EV Cabin Heating Control Using Powertrain Waste Heat

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Solution Overview

Problem

Existing vehicle control systems for hybrid and electric vehicles lack an efficient method to manage waste heat, particularly in economy mode, where heating the cabin while optimizing energy consumption is a challenge.

Innovation Solution

The system incorporates a controller that selectively operates between using a heater and cooling loops to transport waste heat from the powertrain components to the cabin, shutting down the heater in economy mode and utilizing the cooling loops to redirect waste heat for cabin heating, thereby optimizing energy usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the heater is operated to heat the vehicle cabin, then the cabin temperature is maintained comfortably, but energy consumption increases

Engineering Contradiction:

Improvecabin temperatureVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The system converts waste heat from powertrain components (battery, motor, inverter) which would otherwise be discarded to the environment, into a useful resource for heating the vehicle cabin. The cooling loops that normally dissipate heat to ambient surroundings are instead configured to transport this waste heat to the cabin, eliminating the need for separate heating energy consumption.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Temperature

If the cooling loops transport waste heat to ambient surroundings, then powertrain components are cooled effectively, but useful heat energy is lost

Engineering Contradiction:

Improvepowertrain component temperatureVSAvoidwaste heat loss

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The system dynamically reconfigures the cooling loops based on operational mode. In economy mode, the cooling loops are controlled to transport waste heat from powertrain components to the vehicle cabin rather than to ambient surroundings. This dynamic switching allows the same cooling infrastructure to serve dual purposes: cooling powertrain components and heating the cabin, thereby recovering energy that would otherwise be lost.

Inventive Principle:

Principle #15Dynamics

3Use of energy by moving object

If the heater is shut down in economy mode, then energy consumption is reduced, but the cabin may become cold

Engineering Contradiction:

Improveenergy consumptionVSAvoidcabin temperature

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The cooling loops act as an intermediary system that transfers thermal energy from the powertrain components to the vehicle cabin. By using the cooling loops as a heat transport medium, the system can heat the cabin without activating the traditional heater, thus reducing energy consumption while maintaining cabin temperature through waste heat recovery.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enhances energy efficiency by using waste heat for cabin heating in economy mode, reducing energy consumption and extending the vehicle's range while maintaining comfortable cabin temperatures.

Implementation Method 1

The plurality of cooling loops is configured to transport waste heat away from the electric machine, battery, and at least one electrical accessory. The cooling loops are selectively configured to transport the waste heat to ambient surroundings or to the vehicle cabin.

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

The heater is configured to heat a vehicle cabin. The controller is programmed to, in response to the command to heat the vehicle cabin and an absence of the command to operate in the economy mode, operate the heater to heat the vehicle cabin.

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11884132B2Climate control system for a hybrid or electric vehicle

Publication Date: 2024.01.30 FORD GLOBAL TECH LLC

AI summary

A vehicle includes an electrical powertrain, a heater, at least one cooling loop, and a controller. The heater is configured to heat a vehicle cabin. The at least one cooling loop is configured to transport waste heat from at least one subcomponent of the electrical powertrain to the vehicle cabin. The controller is programmed to, in response to a command to heat the vehicle cabin and a command to operate in an economy mode, shut down the heater and operate the at least one cooling loop to transport the waste heat to the vehicle cabin. The controller is further programmed to, in response to the command to heat the vehicle cabin and an absence of the command to operate in the economy mode, operate the heater to heat the vehicle cabin.